Treadmill with dynamic belt tensioning mechanism

ABSTRACT

A dynamic belt-tensioning apparatus for a treadmill includes a base having a first end and a second end spaced from the first end. A foot-striking platform is movably supported by the base so as to allow for vertical movement of the platform during operation of the treadmill. A drive belt has a fixed circumference and is positioned above a top portion of the platform. A drive roller is pivotally mounted adjacent to the first end of the base and engages the drive belt. A bell crank is pivotally coupled to the platform such that pivoting of the bell crank translates into movement of a tensioning roller that is pivotally mounted to the base and that is capable of a range of movement to provide substantially constant tension to the drive belt in response to vertical movement of the platform.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY CLAIM

This application is a continuation of co-pending U.S. patent applicationSer. No. 15/991,891, filed May 29, 2018, titled “Treadmill with DynamicBelt Tensioning Mechanism,” which claims priority benefit of U.S.Provisional Patent App. No. 62/512,770, filed May 31, 2017, titled“Treadmill Dynamic Belt Tensioning Mechanism,” and also U.S. ProvisionalPatent App. No. 62/512,769, filed May 31, 2017, titled “Treadmill withVertically Displaceable Platform.” These applications are assigned tothe same entity as the present application, and are incorporated hereinby reference in the entirety. This application is also related bysubject matter to U.S. patent application Ser. No. 15/991,499, alsofiled on May 29, 2018, titled “Treadmill with Vertically DisplaceablePlatform,” which also claims priority benefit of the two above-listedprovisional applications, and is also assigned to the same entity as thepresent application, and is also incorporated herein by reference in theentirety.

TECHNICAL FIELD

This disclosure describes a dynamic belt-tensioning mechanism for usewith a treadmill.

BACKGROUND

A treadmill has an endless belt powered by a drive roller. The belt isthe surface upon which a user engages in an activity. The endless beltresults in the user being able to engage in an activity in a relativelydefined space.

SUMMARY

This summary is intended to introduce a selection of concepts in asimplified form that are further described below in the detaileddescription section of this disclosure. This summary is not intended toidentify key or essential features of the claimed subject matter, and isalso not intended to be used as an aid in isolation to determine thescope of the claimed subject matter.

In brief, and at a high level, this disclosure describes, among otherthings, dynamic belt-tensioning apparatuses/mechanisms for treadmills aswell as methods of using the same. In one aspect, a dynamicbelt-tensioning apparatus includes a base having a first end and asecond end spaced from the first end, a foot-striking platform capableof vertical movement, a drive belt having a fixed circumference, a driveroller mounted to the base that engages the drive belt, and a tensioningroller that is rotatably mounted on the base and is adapted to movebetween a range of different positions to enable it to providecontinuous tensioning of the drive belt with changes in verticalposition of the platform. The apparatus may include movable componentsthat translate force from the platform to the tensioning roller tofacilitate the maintaining of substantially constant tension on thedrive belt by the tensioning roller.

In one aspect hereof, a dynamic belt-tensioning apparatus for atreadmill is provided. The apparatus includes a base capable of beingpositioned on a solid surface and having a first end and a second endspaced from the first end, a foot-striking platform movably supported bythe base so as to allow vertical movement of the platform duringoperation of the treadmill, a drive belt having a fixed circumferenceand positioned above a top portion of the platform so as to provide amoving foot-engagement surface during operation of the treadmill, adrive roller rotatably mounted adjacent to the first end of the basethat engages the drive belt, and a tensioning roller rotatably mountedto the base and capable of a range of movement to provide substantiallyconstant tension to the drive belt in response to vertical movement ofthe platform.

In another aspect hereof, a dynamic belt-tensioning apparatus for atreadmill is provided. The apparatus comprises a base capable of beingpositioned on a solid surface and having a first end and a second endspaced from the first end and including a first vertically-disposedsupport frame and a second vertically-disposed support frame mounted onopposite sides of the base adjacent to the second end, a foot-strikingplatform movably supported by the base so as to allow vertical movementof the platform during operation of the treadmill, a drive belt having afixed circumference and positioned above a top portion of the platformso as to provide a moving foot-engagement surface during operation ofthe treadmill, a drive roller rotatably mounted adjacent to the firstend of the base that engages the drive belt, and a tensioning rollerhaving a first end rotatably and slidably mounted to the first supportframe and a second end rotatably and slidably mounted to the secondsupport frame. The tensioning roller is capable of a range of movementto provide substantially constant tension to the drive belt in responseto vertical movement of the platform.

In another aspect hereof, a method of tensioning a belt on a treadmillis provided, the treadmill including a base with a platform mountedthereto so that the platform is capable of vertical movement, isprovided. The method comprises driving a belt, engaging a tensioningroller with the belt, and moving the tensioning roller to providesubstantially constant tension to the belt in response to verticalmovement of the platform.

DESCRIPTION OF THE DRAWINGS

Aspects hereof are described in detail herein with reference to theattached drawing figures, in which like numerals refer to like elements,wherein:

FIG. 1 depicts a top perspective view of a treadmill with a dynamicbelt-tensioning mechanism, in accordance with an aspect hereof;

FIG. 2 depicts a side elevation view of the treadmill of FIG. 1 , inaccordance with an aspect hereof;

FIG. 3 depicts a top perspective view of the area designated by thenumeral 3 in FIG. 1 , showing one example of a dynamic belt-tensioningmechanism, in accordance with an aspect hereof;

FIG. 4 depicts a side elevation view of the area designated by thenumeral 4 in FIG. 2 , showing a treadmill platform in an elevatedposition with respect to a treadmill base, in accordance with an aspecthereof;

FIG. 5 depicts a side elevation view similar to FIG. 4 , but insteadshows the treadmill platform in a lowered position with respect to thetreadmill base, in accordance with an aspect hereof;

FIG. 6 depicts a side diagrammatic elevation view of the dynamicbelt-tensioning mechanism shown in FIG. 1 with arrows indicating thedirection of displacement and rotation of the various parts, inaccordance with an aspect hereof;

FIG. 7 depicts a block diagram of an example process for dynamicallytensioning a treadmill belt, in accordance with an aspect hereof; and

FIG. 8 depicts a block diagram of another example process fordynamically tensioning a treadmill belt, in accordance with an aspecthereof.

DETAILED DESCRIPTION

The subject matter of this disclosure is described herein to meetstatutory requirements. However, this description is not intended tolimit the scope hereof. Rather, the claimed subject matter may beembodied in other ways, to include different steps, combinations ofsteps, features, and/or combinations of features, similar to thosedescribed herein, and in conjunction with other present or futuretechnologies. Moreover, although the terms “step” and “block” may beused herein to identify different elements of methods employed, theterms should not be interpreted as implying any particular order amongor between various steps or blocks except when the order is explicitlydescribed and required.

FIGS. 1-7 describe example apparatuses and mechanisms for dynamicallytensioning a belt of a treadmill, as well as methods of using the same.Referring initially to FIG. 1 , a treadmill 10 with a dynamicbelt-tensioning mechanism 12 is depicted, in accordance with an aspecthereof. The treadmill 10 has a base 14 for supporting the treadmill 10on a suitable support surface. The treadmill 10 includes a platform 16that is supported above the base 14 and is vertically movable to anumber of different vertical positions in response to user interactionon an upper surface 18 of the treadmill 10. More specifically, anysuitable structure can be used to support the platform 16 above the base14 to allow the platform 16 to move relative to the base 14 in an up anddown manner (e.g., when a user runs on the platform 16). The up and downmovement of the platform 16 therefore accommodates downward forceexerted by a user on the upper surface 18 when performing, for instance,a running or walking motion. During a running motion, for example, theplatform 16 may be displaced downward (e.g., towards the base 14) as auser's foot strikes the platform 16. Still further, as the user's footis removed during a running motion, the platform 16 may be moved upwardwith a rebound force in preparation for the user's other foot strikingthe upper surface 18. A suitable support structure for supporting theplatform 16 for vertical movement above the base 14 is the scissorframework 20 depicted in FIG. 1 . The scissor framework 20 includes afirst scissor arm 22 pivotally mounted to a second scissor arm 24 at apivot point 26. The arms 22 and 24 are suitably mounted between theplatform 16 and the base 14 to allow the platform 16 to be positioned atvarious heights above the base 14. The scissor framework 20 is but oneexample embodiment that allows for vertical movement of the platform 16with respect to the base 14. Other structures and frameworks such as,for instance, linear bearings and/or tracks can provide the same type ofvertical motion to the platform 16.

Referring now to FIGS. 1-2 , the treadmill 10 also includes anendless/drive belt 28 that provides a moving surface for a user toengage with during usage of the treadmill 10. More specifically, thebelt 28 has a fixed circumference and moves over the upper surface 18 ofthe platform 16. Thus, as a user, for instance, walks or runs, the belt28 is moved beneath the user's feet to allow walking or running at asingle location. In addition to moving over the upper surface 18, thebelt 28 also moves under a bottom plate 30 of the base 14. Morespecifically, referring to FIGS. 1-2 , the bottom plate 30 is supportedabove a ground surface by a plurality of generally trapezoidal legs 32that are also part of the base 14. The legs 32 are positioned along eachedge 34 of the plate 30. Only one of the edges 34 is depicted in FIGS.1-2 , the other being obscured. Still further, the legs 32 along eachedge 34 are connected by a support rib 36 extending downward from alower surface 38 of the bottom plate 30. The provision of a support rib36 along each side of the bottom plate 30 defines a cavity 40 throughwhich the belt 28 passes adjacent the lower surface 38 of the bottomplate 30. In this manner, the belt 28 is able to run in a continuousloop along the upper surface 18 of the platform 16 and along the lowersurface 38 of the bottom plate 30 of the base 14.

Referring still to FIGS. 1-2 , a belt drive mechanism 42 is depicted.The belt drive mechanism 42 serves to provide the endless motion to thebelt 28 so that the user has a continuous running/walking surface as theuser moves across the upper surface 44 of the belt 28. The belt drivemechanism 42 may be used to adjust the speed at which the user runs orwalks. Any suitable control system may be used to adjust the speed ofthe belt drive mechanism 42 and thus the speed of the belt 28 shown inFIGS. 1-2 .

The belt drive mechanism 42 includes a drive roller 46 rotatably mountedto the base 14 by a pair of mounting brackets 48 positioned on oppositesides of the base 14. Only one of the mounting brackets 48 is depictedin FIGS. 1-2 , the other being obscured. The mounting brackets 48 extendupwardly from the plate 30 of the base 14 and each provides a pivotbearing 50 for receiving an axle 52 of the drive roller 46. Theprovision of the axle 52 rotatably mounted in the pivot bearings 50allows for the rotating motion of the drive roller 46. The drive roller46 is coupled to any suitable power source to drive the rotating motionof the drive roller 46 and thus the belt 28. The power source is notdepicted in the figures, but may be any suitable source such as, forexample, an electric motor or a hydraulic motor drivably coupled to thedrive roller 46 by a belt or chain system for example. The power sourcecan also be directly acting on the axle 52 to accomplish the rotatingmotion.

Referring still to FIGS. 1-2 , the treadmill 10 also includes atransition framework 54 for facilitating a smooth transition of the belt28 between the base 14 and the platform 16, particularly as the platform16 is displaced between a number of different vertical positions withrespect to the base 14 during operation of the treadmill 10. Thetransition framework 54 includes a support structure 56 fixedly mountedto the base 14 adjacent to the belt drive mechanism 42. The supportstructure extends along the entire rear edge 58 of the base 14. Thetransition framework 54 further includes a bridge 60 for supporting thebelt 28 as it transitions to the platform upper surface 18 from thedrive roller 46. The bridge 60 is slidably and pivotally mounted to thesupport structure 56 by a pin and slot arrangement 62 adjacent to a rearend 64 of the bridge 60. The bridge 60 is pivotally mounted to theplatform 16 by a pivot arrangement 66 adjacent a forward end 68 of thebridge 60. Thus, as the platform 16 moves in relation to the base 14during operation, the bridge 60 pivots and slides with respect to thebase 14 via the pin and slot arrangement 62. Still further, the bridge60 pivots with respect to the platform 16 via the pivot arrangement 66during vertical movement of the platform 16. In this manner, the bridge60 changes it's angle relative to the platform 16 as the platform 16becomes vertically displaced and thereby provides a smooth transitionsupport surface for the belt 28.

Referring still to FIGS. 1-2 , the platform 16 further includes anoperator support frame 70 that includes a pair of vertically extendingpillars 72 fixedly mounted to opposite sides of the base 14 adjacent thelower ends 74 of the pillars 72. The operator support frame furtherincludes a console 76 mounted between and adjacent to the upper ends 78of the pillars 72. A pair of bracing arms 80 extend rearwardly fromopposite sides of the console 76 to provide lateral support andstability for a user engaging with the platform 16. The console 76 caninclude various sensors and displays, if desired, to monitor or informthe user.

Referring to FIGS. 3-6 , the example dynamic belt-tensioning mechanism12 shown in FIGS. 1-2 is depicted in detail and is disposed adjacent aforward end 82 of the treadmill 10. The tensioning mechanism 12 providesincreased and/or substantially constant tension to the belt 28 as theplatform 16 moves up and down in relation to the base 14. Morespecifically, the belt 28 has a fixed circumference. As the platform 16moves up and down, the spatial relationship between the platform 16 andthe base 14 is dynamically changing. Without the belt-tensioningmechanism 12, slack may exist in the belt 28 as the platform 16 movesdownwardly towards the base 14. This slack may result in possibledisengagement of the belt 28 from the drive roller 46. Still further,the slack may result in an unstable running surface on the upper surface44 of the belt 28. The belt-tensioning mechanism 12 therefore provides asubstantially constant tension in the belt 28 no matter the relativevertical position of the platform 16 above the base 14 using thetensioning mechanism 12.

The dynamic belt-tensioning mechanism 12 includes a pair of supportframes 84 mounted adjacent the forward end 82 of the treadmill 10. Thesupport frames 84 are mounted on the upper surface 85 of the plate 30 ofthe base 14. As depicted in FIG. 1 , the support frames 84 arepositioned on opposite sides of the plate 30 and extend upwardly fromthe upper surface 85. Each of the support frames 84 includes a bellcrank 86 pivotally mounted thereto by a pivot pin 88. Each of the bellcranks 86 includes a rear pivot connection 90 connected to a first end92 of a platform linkage 94 by a pivot/ball joint 96. A second end 98 ofthe platform linkage 94 is pivotally connected to the platform 16 at apivot point 100 by a pivot/ball joint 102. The pivot/ball joints 96 and102 may allow for rotation in all directions to minimize friction andbinding. The pivot connection 90 is located at a rearward end 104 of thebell crank 86. The linkage 94 has a length adjusting turnbuckle 106 thatcan be used to adjust the length of the linkage 94.

A forward end 108 of each bell crank 86 has a forward pivot connection110 connected to a first end 112 of a respective tension roller linkage114 by a pivot pin 116. A second end 118 of each tension roller linkage114 is pivotally connected to a respective tension roller mount 120 bythe pivot pin 116. The tension roller mounts 120 are positioned onopposite sides of the base 14 and serve to rotatably mount a tensionroller 122 by a bearing assembly 124 associated with each of the mounts120. The provision of the mounts 120 and the bearing assemblies 124allow the tension roller 122 to freely rotate. The tension roller 122has a cylindrical surface 126 that engages with an under surface 128 ofthe belt 28. It is this engagement between the surface 126 and the beltsurface 128 that provides the tensioning force on the belt 28 as theplatform 16 moves up and down in relation to the base 14. Each tensionroller linkage 114 has a load cell transducer 130 that may be used formeasuring dynamic belt tension.

Each tension roller mount 120 is slidably connected to a forward end 132of a respective support frame 84 by a slide connection 134. Each slideconnection 134 includes a female slide groove member 136 that is part ofor mounted to the tension roller mount 120 and a male slide protrusionmember 138 that is a part of or mounted to the forward end 132 of thesupport frame 84. With this construction, the mounts 120 and thus thetension roller 122 may have a sliding, linear motion capability withrespect to the forward ends 132 of the support frames 84. It is thissliding motion that facilitates the dynamic tensioning of the belt 28.

In addition to the tension roller 122, an idler roller 140 is alsorotatably mounted between the support frames 84 by bearing arrangements142. The idler roller 140 also has a cylindrical surface 144 thatengages the belt 28 under belt surface 128. The idler roller 140 remainspositionally fixed, but freely rotatable during operation of thetensioning mechanism 12. The idler roller 140 serves to support the belt28 during operation and assist the dynamic tensioning supplied by thelinearly moving tension roller 122.

Referring to FIG. 6 , during operation of the treadmill 10, the spatialposition of the platform 16 changes dynamically in a generally verticaldirection with respect to the base 14 (e.g., moving towards and awayfrom the base 14). As the platform 16 moves downwardly, a downward forceis exerted on the rearward end 104 of the bell crank 86. This downwardforce results in rotation of the bell crank 86 in a clockwise mannerthrough the linkage 94. The clockwise rotation of the bell crank 86results in the generally forward and upward linear movement of mounts120 and thus the tension roller 122 through the provision of the tensionlinkages 114 and the slide connectors 134. The clockwise rotation of thebell crank 86 results in a generally forward and upward force beingapplied to the tension roller 122 via the linkages 114. The female slidegroove member 136 (shown in FIG. 5 ) slides along the male protrusion138 to allow the linear movement of the tension roller 122 to occur. Thedownward movement of the platform 16 results in less space between theplatform 16 and the base 14 such that slack in the fixed circumferencebelt 28 will increase unless addressed by the dynamic tensioningmechanism 12. The generally forward and upward linear movement of thetension roller 122 reduces the slack and assists in keeping asubstantially constant tension on the belt 28.

Still further, as the platform 16 moves upwardly, the bell crank 86 isrotated in a counterclockwise manner through the linkage 94. Thiscounterclockwise rotation of the bell crank 86 results in generallyreward and downward linear motion of the tension roller 122 through theprovision of the linkages 114, the mounts 120, and the slide connections134. Referring back to FIG. 4 , this upward motion of the platform 16 isdepicted. The upward motion of the platform 16 results in a greaterspatial relationship between the platform 16 and the base 14. Therefore,the slack in the fixed circumference belt 28 may be reduced andtherefore may not be as significant. The linear movement of the tensionroller 122 adjusts the tension dynamically in response to the movementof the platform 16. As the platform 16 moves up and down relative to thebase 14, the tension roller 122 is also dynamically sliding along theslide connections 134 to provide substantially constant, or rather,sustained, tension on the belt 28.

Referring to FIG. 7 , a block diagram of an example method 700 fordynamically tensioning a treadmill belt is provided, in accordance withan aspect hereof. At block 146, a treadmill with a base, such as thebase 14 shown in FIG. 1 , with a platform, such as the platform 16 shownin FIG. 1 , mounted thereto to provide vertical movement is provided. Atblock 148, a drive belt, such as the drive belt 28 shown in FIG. 1 , ispowered. At block 150, a tensioning roller, such as the tensioningroller 122, is engaged with the drive belt. At block 152, the tensioningroller is moved to provide sustained contact tension with the drive beltin response to the vertical movement of the platform.

Referring to FIG. 8 , a block diagram of another example process 800 fordynamically tensioning a treadmill belt is provided, in accordance withan aspect hereof. At block 810, a belt, such as the belt 28 shown inFIG. 1 , is driven. At block 820, a tensioning roller, such as thetensioning roller 122 shown in FIG. 6 , is engaged with the belt. Atblock 830, the tensioning roller is moved, such as by using an assemblyof components as shown in FIGS. 5 and 6 , to provide substantiallyconstant tension to the belt in response to vertical movement of atreadmill platform, such as the platform 16 shown in FIG. 1 .

From the foregoing, it will be seen that this invention is one welladapted to attain all the ends and objects hereinabove set forthtogether with other advantages which are obvious and which are inherentto the structure.

It will be understood that certain features and sub-combinations are ofutility and may be employed without reference to other features andsub-combinations. This is contemplated by and is within the scope of theclaims.

While specific elements and steps are discussed in connection to oneanother, it is understood that any element and/or steps provided hereinis contemplated as being combinable with any other elements and/or stepsregardless of explicit provision of the same while still being withinthe scope provided herein. Since many possible embodiments may be madeof the disclosure without departing from the scope thereof, it is to beunderstood that all matter herein set forth or shown in the accompanyingdrawings is to be interpreted as illustrative and not in a limitingsense.

What is claimed is:
 1. A treadmill with a dynamic belt-tensioningmechanism, the treadmill comprising: a support structure; a platformmovably coupled to the support structure; a drive roller rotatablycoupled to the support structure; a tensioning roller rotatably coupledto the support structure; a belt extending over the drive roller, thetensioning roller, and the platform; and a bell crank pivotally coupledto the support structure, wherein pivoting of the bell crank translatesinto movement of the tensioning roller, wherein the tensioning roller iscapable of a range of linear movement at one end of the treadmill thatallows the tensioning roller to dynamically provide substantiallyconstant tension to the belt during movement of the platform.
 2. Thetreadmill of claim 1, wherein the bell crank comprises: a pivot pointcoupled to the support structure, a first connection point coupled tothe tensioning roller, and a second connection point coupled to theplatform.
 3. The treadmill of claim 1, further comprising an idlerroller rotatably coupled to the support structure, wherein the belt alsoextends over the idler roller.
 4. The treadmill of claim 1, wherein thebell crank pivots in response to movement of the platform.
 5. Thetreadmill of claim 1, wherein the bell crank is coupled to thetensioning roller through a linkage.
 6. The treadmill of claim 1,wherein, when the platform moves, the platform and the tensioning rollershift in different directions.
 7. The treadmill of claim 1, wherein thebell crank is coupled to the platform through a linkage.
 8. Thetreadmill of claim 1, wherein the tensioning roller is slidably coupledto the support structure.
 9. The treadmill of claim 1, wherein thesupport structure comprises a frame extending in a direction of movementof the platform, and wherein the bell crank is pivotally coupled to theframe.
 10. The treadmill of claim 1, wherein the bell crank comprises afirst bell crank, wherein the treadmill further comprises a second bellcrank pivotally coupled to the support structure, and wherein the firstbell crank and the second bell crank are respectively positionedadjacent to opposite sides of the support structure.
 11. The treadmillof claim 1, further comprising a platform linkage connecting theplatform and the bell crank, wherein the platform linkage has anadjustable length.
 12. A method of dynamically tensioning a belt on atreadmill, the treadmill comprising a treadmill platform, a platformlinkage, a bell crank, and the belt, the method comprising: driving thebelt over the treadmill platform; shifting the platform in a firstlinear direction, wherein shifting the platform in the first lineardirection causes shifting of the platform linkage in a second lineardirection at an acute angle relative to the first linear direction, andwherein shifting of the platform linkage in the second linear directionapplies a force in the first linear direction to the bell crank thatrotates the bell crank through the platform linkage; and transferringthe force from the bell crank that is rotated to a tensioning roller toincrease tension on the belt.
 13. The method of claim 12, wherein theplatform linkage has an adjustable length.
 14. The method of claim 12,wherein rotating the bell crank comprises: pivoting a pivot point of thebell crank that is coupled to a treadmill support structure, pivoting afirst connection point of the bell crank that is coupled to thetensioning roller, and pivoting a second connection point of the bellcrank that is coupled to the platform linkage.
 15. A belt-tensioningmechanism for a treadmill, the belt-tensioning mechanism comprising: abell crank rotatably coupled to a pivot pin, the bell crank comprising afirst pivot connection and a second pivot connection; a platform linkagehaving a first end and a second end, the first end of the platformlinkage pivotally attachable to the bell crank at the first pivotconnection and the second end of the platform linkage pivotallyattachable to a treadmill platform; and a tensioning roller linkagehaving a first end and a second end, the first end of the tensioningroller linkage pivotally attachable to the bell crank at the secondpivot connection, and the second end of the tensioning roller linkageattachable to a tensioning roller, such that shifting of the platformlinkage in a first direction rotates the bell crank to translate thetensioning roller linkage in a second direction.
 16. The belt-tensioningmechanism of claim 15, wherein the bell crank comprises a first bellcrank, wherein the belt-tensioning mechanism further comprises a secondbell crank.
 17. The belt-tensioning mechanism of claim 16, wherein thefirst bell crank and the second bell crank are mounted on a supportstructure, such that the first bell crank and the second bell crankpivot in unison.
 18. The belt-tensioning mechanism of claim 15, furthercomprising a slide connection that is coupled to the tensioning rollerlinkage.
 19. The belt-tensioning mechanism of claim 15, wherein theplatform linkage has an adjustable length.
 20. The belt-tensioningmechanism of claim 15, further comprising a load cell transducer coupledbetween the tensioning roller linkage and the bell crank.